Process for producing decorative pile fabrics

ABSTRACT

A multicolored decorative pile fabric is disclosed and claimed herein, said fabric being made up of a plurality of selectively shaped pile fabric sections of at least two different colors. The sections have a substantially uniform pile height and density and the fiber grain of all sections is aligned. Adjacent fabric sections are adhesively secured to a backing material with substantially no pile fibers being adhesively secured in the joint between the sections. The peripheral edges of the sections are sufficiently close to provide a substantially uniform pile surface thereacross. A process for producing the decorative pile fabric is also disclosed and claimed herein and includes the steps of providing selectively shaped pile fabric sections having substantially uniform pile height and density and at least two different colors, positioning said sections in close proximity according to a predetermined pattern, said sections being sufficiently close to provide a substantially uniform pile fabric, the fiber grain of all sections being similar; precluding substantially any pile fibers from extending downwardly betwen said sections and adhesively bonding the sections to a backing material.

Kunak et a1.

[ PROCESS FOR PRODUCING DECORATIVE PILE FABRICS [75] Inventors: Anthony F. Kunak; Andrew Falatok,

both of Spartanburg, S.C.

[73] Assignee: Atteny, Inc., Spartanburg, S.C.

22 Filed: 0a. 16, 1972 [21] Appl. No.: 297,773

[52] US. Cl 156/304; 161/37 [51] Int. Cl. B29c 19/00 [58] Field of Search 161/36, 37, 38, 62, 67; 156/304 [56] References Cited UNITED STATES PATENTS 1,917,430 7/1933 Clark 156/304 1,947,152 2/1934 Clark 161/37 2,012,929 8/1935 Knowland 161/67 X 2,055,464 9/1936 Bowes 117/56 2,118,522 5/1938 Pitmam 156/304 2,209,247 7/1940 Dildilian 156/304 2,480,004 8/1949 Dildilian 161/67 X 2,510,563 6/1950 Dow 161/36 2,524,456 10/1950 Masland.... 161/36 2,567,951 9/1951 Lewis 161/36 2,705,693 4/1955 Dildilian et al. 156/304 3,077,429 2/1963 Carrigan 161/67 X 3,219,508 11/1965 Studer 161/36 X 3,484,316 12/1969 Dirrim 161/67 3,531,342 9/1970 Dorn 161/62 3,533,876 10/1970 Burgess 156/304 May 20, 1975 3,711,349 1/1973 Snyder 156/304 x FOREIGN PATENTS OR APPLICATIONS 562,724 9/1958 Canada 161/67 Primary ExaminerWilliam E. Schulz Attorney, Agent, or Firm-Wellington M. Manning, Jr.

[57] ABSTRACT A multicolored decorative pile fabric is disclosed and claimed herein, said fabric being made up of a plurality of selectively shaped pile fabric sections of at least two different colors. The sections have a substantially uniform pile height and density and the fiber grain of all sections is aligned. Adjacent fabric sections are adhesively secured to a backing material with substantially no pile fibers being adhesively secured in the joint between the sections. The peripheral edges of the sections are sufficiently close to provide a substantially uniform pile surface thereacross. A process for producing the decorative pile fabric is also disclosed and claimed herein and includes the steps of providing selectively shaped pile fabric sections having substantially uniform pile height and density and at least two different colors, positioning said sections in close proximity according to a predetermined pattern, said sections being sufficiently close to provide a substantially uniform pile fabric, the fiber grain of all sections being similar; precluding substantially any pile fibers from extending downwardly betwen said sections and adhesively bonding the sections to a backing material.

4 Claims, 4 Drawing Figures PROCESS FOR PRODUCING DECORATIVE PILE FABRICS BACKGROUND OF THE INVENTION The present invention relates to improved decorative pile fabrics and an improved method for making such fabrics. Pile fabrics produced according to the present invention are suitable for such uses as decorative emblems, novelty items, upholstery material, pillow covers, floor coverings, wall coverings and the like.

It has heretofore been'the practice to combine two or more fabrics by various methods, such as by sewing or securing the fabrics together by means of an underlying narrow strip of tape cemented to the back of the fabrics along their adjacent edges. The prior methods for producing decorative pile fabrics from a plurality of shaped fabrics has proved extremely difficult, if not impossible, to produce satisfactory multicolored decorative fabrics. For example, fabrics produced according to the prior art teachings lack pile uniformity; surfaces adjacent the junction of the shaped fabrics are nonuniform and irregular; the point of junction of the fabrics is readily apparent, and the fabrics in general do not enjoy a long useful life.

The present invention has overcome the aforementioned problems whereby a novel composite decorative pile fabric is now available that is both aesthetically pleasing and functionally sound. Further, the prior art does not teach or suggest the product or process of the present invention. Exemplary of the prior art are US. Pat. Nos. 1,947,152 to Clark; 2,012,929 to Knowland; 2,055,464 to Bowes; and 3,484,316 to Dirrim.

SUMMARY OF THE INVENTION It is an object of the present invention to provide multicolored decorative pile fabrics having a uniform pile surface.

Another object of the present invention is to provide a decorative pile fabric having a different colored pile fabric insert of a predetermined design therein.

Another object of this invention is to provide an improved process for producing a multicolored pile fabl'lC.

Yet another object of the present invention is to provide an improved process for uniting pile fabric sections of different colors to form a composite thereof.

In accordance with the present invention, the multicolored decorative pile fabric generally comprises a plurality of selectively shaped pile fabric sections of at least two different colors, the face of said fabric having a substantially uniform pile height and density, the fiber grain of all said sections being in substantial alignment, said fabric sections being adhesively bonded to a backing material at least in localized areas where fabric sections are joined, said sections being positioned such that adjoining peripheral edges thereof are sufficiently close to provide a substantially uniform pile surface thereacross with substantially no pile fibers being bound between said sections. p

More specifically the fabrics of the present invention are preferably produced by cutting out a predetermined shape of a first fabric section and inserting therefor a like shape and size of a different colored'fabric section, the pile fibers of said sections being uniform in height and density, and most preferably being the same type fiber.

The face of the decorative fabrics produced hereby is substantially uniform with the exception of the color (i.e., a substantially uniform pile height,'fiber weight and fiber density, as well as having the grain of the fibers substantially aligned). The plurality of pile fabric sections are adhesively bonded to a backing material, preferably being substantially uniformly bonded at least in the localized area wherein the shaped pile fabric sections are joined together. The adjoining peripheral edges of the fabric sections joined together must be sufficiently close together to provide a substantially uniform pile surface. Preferably, the adjoining edges are in juxtaposition to one another (i.e., closely abut) throughout their perimeter. In order to avoid gaps or distortions in the pile surface, the adjacent sections must fit closely and substantially no fibers of the surface pile of the sections may extend into the joint between the pile fabrics and be adhesively bound therein.

Backing materials used according to the present invention to join adjacent shaped fabric sections may completely cover the back of the fabric sections or may cover only the areas of the section adjacent junctions between sections. Numerous materials are suitable as backings for the instant decorative pile fabrics though cotton duck'or foam are preferred. Moreover, as will be discussed in greater detail hereinafter, the adhesive used to bond the sections to the backing material may be integral with the backing material or separate therefrom. Hence, the backing material may be inherenly adhesive (i.e., a suitable thermoplastic backing fiber or fabric to bond the sections thereto), may have an adhesive precoated thereon, or may receive the adhesive at the time of production of the composite.

Thermoplastic adhesives are preferred for use according to the present invention. Selection of the adhesive depends upon the ultimate use of the fabric. For example, an area floor covering should utilize an adhesive such as a polyurethane that will withstand repeated washing and/or dry cleaning, while other products, such as wall hangings or the like will not require the same durability characteristics for the adhesive. Likewise, while various means of adhesive application are available, film adhesives prelaminated to the backing material are preferred.

The multicolored decorative pile fabrics of this invention are produced by first assembling together at their peripheral edges a plurality of selectively shaped pile fabric sections having a substantially identical and uniform pile surfaces (i.e., substantially the same pile height, fiber weight and fiber density) and having at least two colors between sections. When the sections are assembled, his critical that surface fibers not extend into the joint between the sections and be bound therein. Preferably, the fibers of the pile in the immediate area or vicinity of the joints are aligned in such a manner that they are substantially parallel with relation to each other and extend upwardly away from the section bases. In order to ensure that the surface of the final decorative pile fabric is substantially uniform, the

grain of the fibers on the surface of all the pile fabric sections must be substantially aligned and the peripheral edges of the adjoining pile fabrics must be sufficiently close together so that gaps are not apparent therebetween.

Preferably, the adjoining peripheral edges of the fabric sections are positioned in such a-manner that they are in juxtaposition to one another all along their re- 3 spective adjacent edges. This may be accomplished by carefully cutting the sections and thereafter matching the adjacent edges of the sections with substantially no gaps therebetween. Because such perfect assembling is sometimes not accomplished, the sections can be slid over the thermoplastic adhesive while the adhesive is in its thermoplastic state whereby the back side of the pile fabric sections are held in close abutting relation to each other to present substantially no gap therebetween. The pile on both sides of a joint may be nipped ,to deflect the two edges of fabric closer together and bled shaped pile fabric sections to the backing material is complete.

The selectively shaped pile fabric sections are preferably prepared by cutting the shaped according to predetermined patterns from larger pieces of pile fabric in a manner such that only the backing or supportive portion of the fabric is out without cutting of the pile fibers, per se. If the face fibers of the pile near the edges of the fabric are cut, nonuniformities will be clearly apparent on the surface of the finished decorative structure. In addition, especially in the case of fibers having ;a relatively long pile length, if the face fibers are cut,

minor defects which might sometimes occur in bonding vmay not be covered up by the face fiber bloom. Face fibers could be cut off if the cutting edge is pressed too hard through the pile fabric backing. When cutting pile fabrics from the backing side, only enought pressure to cut the backing should be exerted on the cutting edge. When pile fabrics are cut on the face side of the pile fabric, the cutting edge which may be in the form of a die, must be positioned substantially between the pile to enable the pile fabric to be cut without cutting the face pile fibers. This may be accomplished by utilizing a scribe or the like and running it around the inside of the die to lift the fibers and prevent the die from cutting them off.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top plan view of a decorative pile wall decoration according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the Figures, preferred embodiments of the present invention will now be described in detail. FIG. 1 illustrates a decorative pile fabric for use as a wall decoration, or the like and has a floral motif. A

large first fabric section 1 has been cut to provide a central opening 1' with petals 2 around the outer periphery thereof. A second pile fabric section 3 has been cut and has a shape and size substantially the same as central opening 1' of first section 1. Second fabric section 3 is of a different color than first fabric section 1 and is received .in central opening 1 Pile fiber characteristics of sections 1 and 3, except for color, are preferably identical as to size, length, density and the like. Further sections 1 and 3 have been cut with care so as to avoid cutting of the face pile fibers, whereby overall uniformity of the composite is fostered. With sections 1 and 3 in place, in close juxtaposition, the assembly is heat sealed or otherwise adhesively bonded to a suitable backing material such as a cotton duck fabric (not shown).

FIG. 2 shows a plan view of a further pile fabric having a decorative smile design. The fabric composite 12 of FIG. 2 may be used as a decorative pillow cover and is made up of four shaped pile fabric sections 13, 17, I8 and 19. Base section 13 is cut from a fabric of a particular color according to a predetermined shape, a rectangle as illustrated, with internal openings 14, 15 and 16. Section 17 was cut from a pile fabric of another color having the shape of a mouth, the size corresponding substantially to the size of like shaped opening 16 of section 13. Sections 18 and 19 were cut from further fabric having the color of mouth section 17 or of yet another color in contrast to section 13. Eye sections 18 and 19 are cut to substantially the shape and size of openings 14 and 15 of section 13. With all of the sections in place, the assembly is adhesively bonded to a suitable backing material (not shown).

FIG. 3 shows a cross sectional view of a portion of the decorative cushion cover of FIG. 2, taken along line II- II. The face pile fibers 27 and 27' of shaped pile fabric sections 13 and 17 are joined to and supported by fabric backings 28 and 28', respectively. The two sections of pile fabric meet and have their adjoining peripheral edges in juxtzposition to one another at joint 31. As can be seen from FIG. 3, the face fibers 27 and 27' do not extend down into joint 31. The pile fabric backings 28 and 28' are adhesively bonded to backing material 30 by means of adhesive layer 29. The backing material may be of any suitable material such as a cotton duck or polyurethane foam. The adhesive layer may be of any suitable material, but is preferably a thermoplastic polymeric compound such as a polyurethane, a polyester or a polyamide adhesive composition. Preferably the thermoplastic adhesive will have a melting point of less than about 375 F., though ideally less than about 200. If the pile fabric assembly must be bonded at temperatures much higher than about 375 F., distortion of the final product can result from puckering of the backing material or even the pile fabric. At the lower boding temperatures, there is significantly less differential shrinkage between the components of the pile fabric assembly, which results in virtual elimination of distortion.

FIG. 4 shows a cross sectional view of a pile fabric illustrating a method for straightening the face pile fibers p'rior'to cutting a shaped pile fabric section. A cutting die 34 is first brought into contact with the pile fabric just forward of the particular area being cut. Die 34 is then pulled in the direction of the cutting area to move into the pile fiber area, partially straightening fibers 35. Once the die 34 is in position to make the desired cut, a scribe 32 is brought into contact with the inside surface 33 of die 34 and is moved therearound, following the periphery of the cut to be made. Scribe 32 can be made of any suitable material such as wood, plastic or i 7 metal. I

Position A of FIG. 4 shows scribe 32- being moved into position along inside surface 33 of die cutter 34. Note that pile fibers 35 are still entrapped under die 34 and if the cutting were conducted at this point, a substantial number of fibers 35 would be severed during the cut, whereby a uniform pile surface in the final product would not then result. Instead, a gap would result at the joint between the sections. Theseverity of the gap would depend on the number of pile fibers cut and may, in fact, expose the joint between the assembled sections.

Position B of FIG. 4 shows scribe 32 moving along die 34. As scribe 32 is moved along, the forward point 32 thereof passes under any pile fibers 34 that are en-, trapped by forward cutting edge 34' of die 34. Continued movement of scribe 32 withdraws fibers 34 from under forward cutting edge 34' of die 34. Since no appreciable pressure has yet been applied on die 34, there is very little danger of damaging fibers 35 with scribe 32. After scribe 32 has passed around the inner periphery of die 34, substantially all the pile fibers adjacent die 34 should be removed from beneath the forward cutting edge 34' as shown in position C. Thereafter, pressure may be exerted on die 34 to produce a clean cut of predetermined shape through backing 36 without damaging any substantial number of adjacent pile fibers 35.

In some instances, the backing material to which the pile fabric is adhesively bonded may also have an adhesive coated on its underside to facilitate attaching the decorative pile fabric to a surface such as a wall. Usually the adhesive is protected, such as by a release paper, prior to adhesively bonding the pile fabric assembly to the wall. The pile surface may be comprised of fibers of any fiber-forming material such as polyethylene terephthalate, polycaprolactam, polyhexamethylene adipamide, acrylonitrile polymers containing at least 85 percent acrylonitrile, cellulose triacetate or cellulose acetate. The pile surface fiber height will be substantially uniform, but that height will normally range between 0.l and 1.5 inches.

Decorative pile fabrics according to the present invention may contain virtually any design. Quite often, oppositely colored fabrics are produced where like shaped and sized first sections are provided. Cut outs from each of these sections then provides the further fabric sections for the other first section. In any event, the sections may be designed as desired to provide the ultimate product.

According to the present invention, the process for producing the ultimate fabric proceeds as follows. The mating pile fabric sections are cut so as to avoid any substantial cutting or other damage to the pile fibers adjaceent the cuts. Each cut is made with the fiber grain running in the same'direction, whereby the overall fiber grain will be aligned once the sections are assembled. The shaped fabric sections are then brought together on an assembly table, with the fiber surface down. A backing material, preferably having an adhesive thereon is then placed over the sections, the backing material at least covering the joints between the sections. In this regard, depending on the design and size of the ultimate fabric, the backing material may be one or more pieces.

After the fabric sections have been matched according to the predetermined pattern and the backing material and adhesive properly positioned thereover, heat is 6 appliedgtoihe composite to melt the thermoplastic adhesive and unite the backing material to the fabric sectionsi-Care should; be taken to insure sufficient dwell time at all areas of each joint to insurecomplete bond-' ing. After heat has been applied, preferably by a hot head press at a temperature of less than 375 F., the composite is permitted to cool whereby the backing material is permanently secured to the fabric sections.

With certain designs, it may be further necessary to turn the composite over and further apply pressure along the edges of the sections adjacent each joint to prevent curling at a later date. Also, in the event that a less than perfect fit occurs between sections, the sections may be mannually forced together while the adhesive is pliable and held in place until the adhesive solidifies. Further general precautions are taken to insure that adhesive does not migrate from the backing to the surface of the pile fibers.

Once the composite has been completed, it may further be desirable to treat the underside thereof to apply a pressure sensitive adhesive, a non skid surface or the like. Conventional techniques may be employed. In fact, such treatment may be provided to the backing material prior to securement of the fabric sections. One technique that may be employed is to coat the underside of the backing for the composite with an adhesive or other system containing polymer lumps in colloidal suspension therein. After curing of the coating, the lumps remain to provide an irregular, non skid surface.

Having described the present invention in detail, it is obvious that one skilled in the art will be able to make variations and modifications thereto without departing from the scope of the invention. Accordingly, the scope of the present invention should be determined only by the claims appended hereto.

What is claimed is:

1. A method for producing a multicolored decorative pile fabric comprising:

a. cutting a plurality of selectively shaped pile fabricsections such that the fiber grain of all sections will be in alignment when the sections are joined, said sections having substantially the same pile height and density and at least one different color, said cutting being accomplished by bringing a cutting edge into contact with said pile fabric and removing any pile fibers from under said cutting edge prior to making the cut;

b. assembling said sections on a backing material in substantially abutting relationship according to a predetermined pattern while removing any pile fibers that extend into joints between the sections, said backing material having a thermoplastic adhesive thereon;

c. heating the assembly to a temperature not greater than approximately 375F. for a time sufficient to activate the adhesive;

d. applying pressure along the edges of the sections adjacent the joints to insure a good bond and preclude curling of said edges; and

e. permitting the composite to cool to securely bond the sections together.

2. The method as defined in claim 1 wherein the sections are assembled with the pile fibers down, and wherein after applying pressure around the section edges, the assembly is turned over and pressure is again applied around the edges of the sections.

3. The method as defined in claim 1 wherein pile fibers are removed from beneath said cutting edge by passing a scribe along said cutting edge, lifting all pile rial into abutting engagement with an adjacent section fibers from beneath same. to properly assemble said sections without entrapping 4. The method as defined in. claim 1 wherein the fibers in joints therebetween. edges of said sections are slid along said backing mate- 

1. A METHOD FOR PRODUCING A MULTICOLORED DECORATIVE PILE FABRIC COMPRISING: A. CUTTING A PLURALITY OF SELECTIVELY SHAPED PILE FABRIC SECTIONSSUCH THAT THE FIBER GRAIN OF ALL SECTIONS WILL BE IN ALIGNMENT WHEN THE SECTIONS ARE JOINED, SAID SECTIONS HAVING SUBSTANTIALLY THE SAME PILE HEIGHT AND DENSITY AND AT LEAST ONE DIFFERENT COLOR, SAID CUTTING BEING ACCOMPLISHE BY BRINGING ACUTTING EDGE INTO CONTACT WITH SAID PILE FABRIC AND REMOVING ANY PILE FIBERS FROM UNDER SAID CUTTING EDGE PRIOR TO MAKING THE CUT; B. ASSEMBLING SAIDSECTIONS ON A BACKING MATERIAL IN SUBSTANTIALLY ABUTING RELATIONSHIP ACCORDING TO A PREDETERMINED PATTERN WHILE REMOVING ANY PILE FIBERS THAT EXTEND INTO JOINTS BETWEEN THE SECTIONS, SAID BACKING MATERIAL HAVING ATHERMOPLASTICADHESIVEE THEREON; C. HEATING THE ASSEMBLY TO A TEMPERATURE NOT GREATER THAN APPROXIMATELY 375*F. FOR ATIME SUFFICIENT TO ACTUIVATETHE ADHESIVE; D. APPLYING PRESSURE ALONG THE EDGES OF THE SECTIONS ADJACENT THE JOINTS TO INSURE A GOOD BOND AND PRECLUDE CURLING OF SAID EDGES; AND E. PERMITTING THE COMPOSITE TO COOLTO SECURELY BOND THE SECTIONS TOGETHER.
 2. The method as defined in claim 1 wherein the sections are assembled with the pile fibers down, and wherein after applying pressure around the section edges, the assembly is turned over and pressure is again applied around the edges of the sections.
 3. The method as defined in claim 1 wherein pile fibers are removed from beneath said cutting edge by passing a scribe along said cutting edge, lifting all pile fibers from beneath same.
 4. The method as defined in claim 1 wherein the edges of said sections are slid along said backing material into abutting engagement with an adjacent section to properly assemble said sections without entrapping fibers in joints therebetween. 